We’ve Got A Saxaboom At Home Son

May 21, 2023 by Matthew Carlson 6 Comments

Most parents have heard a familiar story. Their lovely child comes up, having seen a celebrity rocking out with a funny $20 toy from the 80s, and asks for it. Of course, you reply, it’s just 20 dollars. However, a quick scan through eBay reveals that everyone else’s kid has also been asking for this obscure toy for a school event, which now costs around $700. [Ben] found himself in that exact position and made a crucial off-hand comment, “I bet I could make one of those.” That was how his hectic journey into the world of toy reproduction began.

All [Ben] had for reference when recreating a Sax-A-Boom were pictures and sound clips. Modeling complex sweeping shapes in CAD is difficult, and [Ben] commissioned a 3d model from a professional on Fiverr. [Ben] broke down the model into printable sections and tweaked it to account for buttons. After a concerning amount of putty, wet sanding, and elbow grease, [Ben] had a decently smooth body for an instrument. The device’s guts is an ESP32-based board called Sonatino, built around music generation. The music samples came from a virtual instrument clone on GitHub and loaded onto an SD card.

Time pressure crept in towards the end, and [Ben] had to go for some dirty solution that he would have preferred (popsicle sticks and epoxy for button mounting). Yes, there were some gaps and paint flaws, but ultimately [Ben’s] son rocked the school presentation. It’s a beautiful journey through creating something with a high level of finish on a limited timescale.

Perhaps future versions of the Sax-A-Boom can take it further by adding a breath sensor, like this 3d printed MIDI instrument.

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Reverse Engineering An Oil Burner Comms Board, With A Few Lucky Breaks

May 11, 2023 by Dan Maloney 3 Comments

Here’s a question for you: How do you reverse engineer a circuit when you don’t even have it in hand? It’s an interesting problem, and it adds a level of difficulty to the already iffy proposition that reverse engineering generally presents. And yet, not only did [themole] find a way to replicate a comms board for his oil burner, he extended and enhanced the circuit for integration into his home automation network.

By way of backstory, [themole] has a wonky Buderus oil burner, which occasionally goes into safety mode and shuts down. With one too many cold showers as a result, he looked for ways to communicate with the burner controller. Luckily, Buderus sells just the thing — a serial port module that plugs into a spare slot in the controller. Unluckily, the board costs a bundle, and that’s even if you can find it. So armed with nothing but photos of the front and back of the board, the finding of which was a true stroke of luck, he set about figuring out the circuit.

With only a dozen components or so and a couple of connectors, the OEM board gave up its secrets pretty easily; it’s really just a level shifter to make the boiler talk RS-232. But that’s a little passé these days, and [the78mole] was more interested in a WiFi connection. So his version of the card includes an ESP32 module, which handles wireless duties as well as the logic needed to talk to the burner using the Buderus proprietary protocol. The module plugs right into the burner controller and connects it to ESPHome, so no more cold showers for [themole].

We thought this one was pretty cool, especially the way [themole] used the online photos of the board to not only trace the circuit but to get accurate — mostly — measurements of the board using an online measuring tool. That’s a tip we’ll keep in our back pocket.

Thanks to [Jieffe] for the tip.

Tiny Microcontroller Uses Real-Time Operating System

May 10, 2023 by Bryan Cockfield 51 Comments

Most of the computers we interact with on a day-to-day basis use an operating system designed for flexibility. While these are great tools for getting work done or scrolling your favorite sites, they have a weakness when it comes to interacting quickly with a real-world environment. For these kinds of low-latency, high-reliability systems you may want to turn to something like freeRTOS which is optimized for this kind of application and which [Parikshit Pagare] has used to build his home automation system.

This build is based around an ESP32 for which freeRTOS, designed specifically for embedded systems, is uniquely suited. There are several channels built in capable of monitoring temperature, functioning as a smoke alarm, and sensing whether someone is at the front door. All of these are reported to a small OLED screen but are also updated on an Android app as well, which happens nearly instantaneously thanks to the real-time operating system. There are a number of user-controllable switches as well that are capable of turning lights or fans on and off.

For a home automation system, it’s one of the most low-cost and fully-featured we’ve seen and if you’re still having trouble coming across a Raspberry Pi as they sort out supply issues, something like this might make an excellent substitute at a fraction of the price. If you’re looking to expand even beyond this build, one of the gold standards for ESP32-based automation design is this build from [Marcus] which not only demonstrates how to build a system like this but goes into great detail on the ESPHome environment.

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Holograms Display Time With ESP32

May 5, 2023 by Bryan Cockfield 30 Comments

Holograms and holographic imagery are typically viewed within the frame of science fiction, with perhaps the most iconic examples being Princess Leia’s message to Obi-Wan in Star Wars, or the holodecks from Star Trek. In reality, holograms have been around for a surprising amount of time, with early holographic images being produced in the late 1940s. There are plenty of uses outside of imagery for modern holographic systems as well, and it’s a common enough technology that it’s possible to construct one using an ESP32 as well.

In this build, [Fiberpunk] demonstrates the construction and operation of a holographic clock. The image is three-dimensional and somewhat transparent and is driven by an ESP32 microcontroller. The display is based around a beamsplitter prism which, when viewed from the front, is almost completely invisible to the viewer. The ESP32 is housed in a casing beneath this prism, and [Fiberpunk] has two firmware versions available for the device. The first is the clock which displays an image as well as the time, and the second is more of a demonstration which can show more in-depth 3D videos using gcode models and also has motion sensing controls.

For anyone interested in holography, a platform like this is might make an excellent entry point to explore, and with the source for this build available becomes even easier. It’s almost certainly less expensive than these 3D printers that can turn out custom holographic images, and has the added benefit of being customizable and programmable as well.

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A view of the inside of a car, with drivers wheel on the left and control panel in the middle, with red LED light displayed in the floor area under the drivers wheel and passenger side.

Bass Reactive LEDs For Your Car

April 25, 2023 by Abe Connelly 32 Comments

[Stephen Carey] wanted to spruce up his car with sound reactive LEDs but couldn’t quite find the right project online. Instead, he wound up assembling a custom bass reactive LED display using an ESP32.

The entirety of the build is minimal, consisting of a GY-MAX4466 electret microphone module, a KY-040 encoder for some user control and an ESP32 attached to a Neopixel strip. The only additional electronic parts are some passive resistors to limit current on the data lines and a capacitor for power line noise suppression. [Stephen] uses various enclosures from Thingiverse for the microphone, rotary encoder and ESP32 box to make sure all the modules are protected and accessible.

The magic, of course, is in the software, with the CircuitPythyon ulab library used to do the heavy lifting of creating the spectrogram and frequency filtering. [Stephen] has made the code is available on GitHub for those wanting to take a closer look.

It wasn’t very long ago that sound reactive LEDs used to be a heavy lift, requiring optimized FFT libraries or specialized components to do the spectrogram. With faster and cheaper microcontroller boards, we’re seeing many great projects, like the sensory bridge or Raspberry Pi driven LED spectrogram, that can now take spectrograms and Fourier transform calculations as basic infrastructure to build on top of them. We’re happy to see [Stephen] leverage the ESP32’s speed and various circuit Python libraries to create a very cool LED car hack.

Video after the break!

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Rickrolling SSID With ESP32

April 23, 2023 by Joseph Long 8 Comments

Reddit user [nomoreimfull] posted code for a dynamic WiFi beacon to r/arduino. The simple, but clever, sketch is preloaded with some rather familiar lyrics and is configured to Rickroll wireless LAN users via the broadcast SSID (service set identifier) of an ESP32 WiFi radio.

The ESP32 and its smaller sibling the ESP8266 are tiny microcontrollers that featuring built-in WiFi support. With their miniature size, price, and power consumption characteristics, they’ve become favorites for makers, hackers, and yes pranksters for a wide variety of projects. They can be easily programmed using their own SDK or through a “board support” extension to the Arduino IDE.

For the dynamic WiFi beacon, the ESP32 is placed into AP (access point) mode and broadcasts its human readable name (SSID) as configured. What makes the SSID dynamic, or rolling, is that the sketch periodically updates the SSID to a next line of text stored within the code. Of course, in the Rickroll prank this means the next line of lyrics from “Never Gonna Give You Up” by Rick Astley himself.

Always a favorite prank, we’ve seen Rickrolls take the form of IR remote controls , free WiFi servers, and coin cell throwies.

Rick Astley picture: Wjack12, CC BY-SA 4.0.

Single Flex PCB Folds Into A Four-Wheel Rover, Complete With Motors

March 25, 2023 by Dan Maloney 3 Comments

You’ve got to hand it to [Carl Bugeja] — he comes up with some of the most interesting electromechanical designs we’ve seen. His latest project is right up there, too: a single PCB that folds up into a four-wheel motorized rover.

The key to [Carl]’s design lies with his PCB brushless motors, which he has been refining since we first spotted them back in 2018. The idea is to use traces on the PCB for the stator coils to drive a 3D printed rotor containing tiny magnets. They work surprisingly well, even if they don’t generate a huge amount of torque. [Carl]’s flexible PCB design, which incorporates metal stiffeners, is a bit like an unfolded cardboard box, with two pairs of motor coils on each of the side panels. This leaves the other surfaces available for all the electronics, with includes a PIC, a driver chip, and a Hall sensor for each motor, an IMU and proximity sensor for navigation, and an ESP32 to run the show.

With machined aluminum rotors and TPU tires mounted to the folded-up chassis, it was off to the races, albeit slowly. The lack of torque from the motors and the light weight of the rover, along with some unwanted friction due to ill-fitting joints, added up to slow progress, especially on anything other than a dead flat surface. But with some tweaking, [Carl] was able to get the buggy working well enough to call this one a win. Check out the build and testing in the video below.

Knowing [Carl], this isn’t the last we’ll see of the foldable rover. After all, he stuck with his two-wheel PCB motor design and eventually got that running pretty well. We’ll be keeping an eye out for progress on this one.

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